We discuss the development of a grain-continuum model to examine the effects of thermally induced stress in 3D IC inter-wafer vias. We demonstrate the approach using stress-driven grain boundary migration in polycrystalline copper films, assuming that migration is due to vacancy migration. The anisotropic elastic constants of single crystal Cu are used for each grain, after aligning them with each grain's orientation. Stresses are thermally induced in a series of films, including one with a dominant <111> texture surrounding a single <100> grain. Grain boundary velocities are calculated from the fluxes of vacancies to grain boundaries. The computed velocities are then used to update the level sets that represent the grain boundaries using the PLENTE software.We present the status of our thermo-mechanical modeling effort to provide parameters for the design and fabrication of 3D ICs based on benzocylcobutene (BCB) wafer bonding [1]. Broadly speaking, the stability concerns for inter-wafer Cu vias in 3D ICs are extensions of those for Cu-based MLM structures. For 3D ICs, a major reliability concern is the stability of the vias, which pass through several materials/layers.We have used Comsol Multiphysics (CM) [2] in thermomechanical modeling of inter-wafer Cu vias. Using structures such as the one displayed in Fig. 1a, we treated Cu as a homogenous material placed under stress from CTE mismatches with surrounding materials. We concluded that the inter-wafer vias are susceptible to failure, depending on the BCB thickness, via pitch, and via diameter. The impact of grain structure on these systems was introduced via a HallPetch correlation of the Cu yield stress with grain size. We validated our approach by comparing our results to data from reliability studies of Cu via structures in SiCOH and SiLK [3,4], as well as XRD studies of damascene-patterned Cu lines [5]. Since these results indicate that stresses are a potential reliability issue, we are extending our model in order to improve on our predicted design parameters and examine the types of potential failures.Because the smallest dimensions of the structures in question are on the same length scale as the grains within the Cu, the granular nature of the Cu may have a significant effect on the mechanical response of the system [6]. Moreover, the homogeneous isotropic results show large gradients in the stresses, which may provide driving forces for grain structure evolution. We report on efforts to include polycrystallinity into thermal mechanical models and to consider the effects of anisotropy and potential grain structure evolution. To include such crystallinitiy, we formulate 'grain-continuum' models, in which each grain is treated as a continuum, while grain boundaries are separately represented [7].
Effects of elastic anisotropyCu grains are anisotropic. The elastic modulus for single crystal Cu is 2.9 times larger in the <111> direction and 2.0 times larger in the <110> than it is in the <100> direction Springer